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Paper or paperboard having nanofiber layer and process for manufacturing same

a technology of paper or paperboard and nanofibers, which is applied in the direction of papermaking, non-fibrous pulp addition, coating, etc., can solve the problems of high cost, high coating weight, and increase in the basis weight of finished paper,

Inactive Publication Date: 2006-11-30
MEADWESTVACO CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0011] The present invention relates to paper or paperboard containing a secondary web of nanofibers on a base web of cellulose fibers. The invention also relates to methods for manufacturing the described paper or paperboard products. In accordance with one aspect of the invention, a plurality of nanofibers are applied to a web of cellulose paper fibers to produce a composite paper web comprising a nanoweb and the base cellulose fiber web. In accordance with a particular embodiment of the invention, the nanofibers are applied to the web of paper fibers at a dryness level of the paper fiber web of about 40% to about 100% by weight. In accordance with another embodiment of the invention, a binder is provided between the nanoweb and the cellulose web to improve bonding therebetween.

Problems solved by technology

However, paper-coating equipment can be very complex and expensive.
Such a relatively high coat weight can result in substantial expenses with respect to coating materials and result in an increase in the basis weight of the finished paper.
A high coat weight is usually required because lower coating weights are typically not uniform enough to provide the desired improvement in surface properties.
Non-uniformity associated with low coating weights can be particularly problematic when coating unbleached board.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0029] A polymer solution can be prepared according to the following formulation:

% by weight wetPolyvinyl Alcohol (PVOH)10%Surfactant - Triton X4000.5% Plastic Pigment - Omnova 220310%MF cross-linker - Cymel 38510%H2Obalance

[0030] The nanofiber formulation can be applied with an electrospinning device at a voltage of about 80 kV and electric current of about 50-400 microampere. The nanofibers are ejected from an orifice having a diameter of about 2 mm. The resulting nanofibers have an average diameter of about 200 microns. The nanofibers are applied to an unbleached board substrate having a basis weight of about 300 gsm. The nanofibers are applied at a coat weight of about 5 gsm. In accordance with this example, the nanofibers are applied in the drying section of the paper machine at a dryness level of the base stock prior to coating of about 60% (i.e., 40% wet). The composite paper can have a Parker Print smoothness of about 1.5 microns and a brightness of about 90%.

example 2

[0031] A composite sheet can be prepared as in Example 1 and further provided with a binder to improve adhesion of the nanofibers to the base stock. A binder composition comprising about a 5% aqueous solution of polyvinyl alcohol can be applied to the base stock before the nanofibers. In this example, the binder is applied at a dry coat weight of about 1 gsm. The binder may be applied at a dryness level of about 55% by weight and then the nanofibers are applied at a dryness level of about 60%.

[0032] The finished sheet of Example 2 exhibits improved adhesion compared to a sheet prepared in accordance with Example 1. Adhesion can be measured in accordance with an IGT Reprotest using an AIC2-5 printability tester. The test can be conducted according to PAPRO Method 2.403 and ISO 3782, 3783. Results are provided in the following table.

TABLE 1SampleIGTExample 170Example 2100

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Abstract

A method for forming a web or paper or paperboard includes forming a web of cellulose paper fibers and producing a nanoweb of nanofibers on the web of cellulose paper fibers.

Description

BACKGROUND OF THE INVENTION [0001] The present invention relates to a method for manufacturing a web of paper or paperboard. More particularly, the invention relates to a paper or paperboard manufacturing method comprising the steps of forming a web of cellulose paper fibers, producing a plurality of nanofibers and applying the nanofibers to the web to produce a composite paper web comprising a nanoweb layer and a cellulose-fiber layer. [0002] Paper is manufactured by an essentially continuous production process wherein a dilute aqueous slurry of cellulosic fiber flows into the wet end of a paper machine and a consolidated dried web of indefinite length emerges continuously from the paper machine dry end. The wet end of the paper machine comprises one or more headboxes, a drainage section and a press section. The dry end of a modern paper machine comprises a multiplicity of steam heated, rotating shell cylinders distributed along a serpentine web traveling route under a heat confini...

Claims

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Application Information

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IPC IPC(8): D21F11/00B05D1/12
CPCB32B29/02D21H19/82D21H23/50D21H23/26D21H21/52
Inventor KNOX, DAVID E.KLEIN, EDWARD P.BABINSKY, VLADISLAV A.SCOTT, ASHLEY S.
Owner MEADWESTVACO CORP